Production process for aromatic thioether ketone/thioether sulfone copolymers

ABSTRACT

Disclosed herein are an aromatic thioether ketone/thioether sulfone random copolymer comprising phenylene thioether ketone recurring units (I) and phenylene thioether sulfone recurring units (II), (a) the compositional ratio (I:II) of the recurring units (I) to the recurring units (II) ranging from 98:2 to 65:35, (b) the solution viscosity (η inh ) being at least 0.3 dl/g, (c) the melt crystallization time (τ) being at least 3 minutes, (d) the melting point (Tm) being 300°-350° C., (e) the glass transition temperature being at least 125° C., (f) the retention (400° C./20 min) of melt crystallization enthalpy (ΔHmc) being at least 60%, and (g) the average particle size being at least 0.1 mm, and the production process thereof.

This application is a division of application Ser. No. 08/003,034 filedJan. 12, 1993, now U.S. Pat. No. 5,369,191.

FIELD OF THE INVENTION

This invention relates to aromatic thioether ketone/thioether sulfonecopolymers combining a high melting point with a high glass transitiontemperature, and at the same time having sufficient melt stability,excellent extrudability and excellent stretch-processability of theextrudate, and a process for the production thereof. The aromaticthioether ketone/thioether sulfone copolymers according to thisinvention can be used in various kinds of formed products, for example,films and fibers.

BACKGROUND OF THE INVENTION

In the fields of the electronic and electrical industry and theautomobile, aircraft and space industries, there is a strong demand inrecent years for crystalline thermoplastic resins having high heatresistance of 300° C. or higher in terms of melting point and moreovereasy melt processability. Among these crystalline thermoplastic resinshaving high heat resistance, poly(arylene thioether-ketones)(hereinafter abbreviated as "PTKs") are ultrahigh-heat-resistantaromatic polymers combining a high melting point of about 350° C. with ahigh glass transition temperature of about 135° C. There is hence astrong demand for provision of such polymers in the fields of frontiertechnologies, and the like.

PTKs can be produced by causing an alkali metal sulfide and a4,4'-dihalobenzophenone to undergo a dehalogenation and sulfurizationreaction in an organic amide solvent (Japanese Patent ApplicationLaid-Open No. 54031/1989). However, PTKs involved a problem that whenthey are formed and processed by, for example, extrusion and subsequentstretching or sheet forming, it is considerably difficult from thetechnical viewpoint to apply these forming and processing methodsthereto. This problem was believed to be attributed to the formation ofcoarse spherulites in a product formed by the extrusion owing to the toohigh crystallization.

In order to lower the crystallization rate of a PTK, the presentinventor attempted to reduce the crystallinity and crystallization rateof the PTK by random copolymerization of its monomer with monomers of akind different from the first-mentioned monomer. Namely, a4,4'-dihalobenzophenone as a dihalogenated aromatic compound wascombined with dihalobenzenes as dihalogenated aromatic compounds of akind different from the 4,4'-dihalobenzophenone, respectively, followedby their reaction with an alkali metal sulfide, thereby producing anaromatic thioether ketone/thioether random copolymer somewhat lowered incrystallinity. However, it was difficult to obtain a random copolymerhaving a high molecular weight in the form of granules because the4,4'-dihalobenzophenone and dihalobenzenes were different in reactivityfrom each other.

On the other hand, there has been proposed a block copolymer containingpoly(arylene thioether-ketone) blocks and poly(arylene thioether) blocks(Japanese Patent Application Laid-Open No. 225527/1990). This blockcopolymer can be obtained by a process in which an alkali metal sulfideis reacted with a 4,4'-dihalobenzophenone in the presence of apoly(arylene thioether) prepolymer having reactive terminal groups toform a poly(arylene thioetherketone) block, or a process in which apoly(arylene thioether) prepolymer having reactive terminal groups isreacted with a poly(arylene thioether-ketone) prepolymer having reactiveterminal groups. It is possible to collect a polymer moderately reducedin crystallization rate by suitably selecting reaction conditions in theproduction process. However, this block copolymer involves problems suchthat its melting point and glass transition temperature are lowered to aconsiderable extent compared with the PTK homopolymer, and itspolymerization operation is complicated.

OBJECTS AND SUMMARY OF THE INVENTION

It is an object of this invention to provide aromatic polymers whichhave predominant recurring units composed of arylene thioether andexcellent extrudability and excellent stretch-processability of theextrudate, combine a high melting point with a high glass transitiontemperature, possess sufficient melt stability, and are in the form ofgranules.

The present inventors carried out an extensive investigation with a viewtoward solving the above-described problems involved in the prior art.As a result, it was found that when a 4,4'-dihalobenzophenone as adihalogenated aromatic compound is combined with a4,4'-dihalodiphenylsulfone as a dihalogenated aromatic compound of akind different from the 4,4'-dihalobenzophenone, followed by theirreaction with an alkali metal sulfide, an aromatic thioetherketone/thioether sulfone random copolymer having a high molecular weightcan be obtained with comparative ease. The thus-obtained aromaticthioether ketone/thioether sulfone copolymer had moderately reducedcrystallinity, a high melting point and moreover a glass transitiontemperature higher than that of the PTK homopolymer.

The present inventors have conducted a further investigation. As aresult, it has also been found that when proportion of the4,4'-dihalobenzophenone to the 4,4'-dihalodiphenylsulfone is selectivelylimited to a specific range, a copolymer moderately reduced incrystallization rate can be obtained in the form of granules.

The present invention has been brought to completion on the basis ofthese findings.

According to this invention, there is thus provided an aromaticthioether ketone/thioether sulfone random copolymer comprising recurringunits of the formula (I): ##STR1## and recurring units of the formula(II): ##STR2##

(a) the compositional ratio (I:II) of the recurring units (I) to therecurring units (II) ranging from 98:2 to 65:35,

(b) the solution viscosity (η_(inh)) being at least 0.3 dl/g asdetermined by viscosity measurement at 30° C. and a polymerconcentration of 0.4 g/dl in a 1:1 (by weight) mixed solvent ofm-chlorophenol and 1,2,4-trichlorobenzene,

(c) the melt crystallization time (τ) being at least 3 minutes,

(d) the melting point (Tm) being 300°-350° C.,

(e) the glass transition temperature being at least 125° C.,

(f) the retention (400° C./20 min) of melt crystallization enthalpy(ΔHmc) being at least 60%, wherein the ΔHmc retention (400° C./20 min)is determined by measuring, by means of a differential scanningcalorimeter, (1) melt crystallization enthalpy, ΔHmc (400° C./1 min) and(2) melt crystallization enthalpy, ΔHmc (400° C./21 min) when cooled ata rate of 10° C./min from 400° C. after the copolymer is held at 50° C.for 5 minutes in an inert gas atmosphere, heated to 400° C. at a rate of100° C./min and then held, respectively, for 1 minute at 400° C. and for21 minutes at 400° C., and then calculating the retention in accordancewith the following equation:

    ΔHmc retention (400° C./20 min)=[ΔHmc (400° C./21 min)/ΔHmc (400° C./1 min)]×100,

and

(g) the average particle size being at least 0.1 mm.

According to this invention, there is also provided a process for theproduction of an aromatic thioether ketone/thioether sulfone copolymer,which comprises reacting an alkali metal sulfide with dihalogenatedaromatic compounds including a 4,4'-dihalobenzophenone and a4,4'-dihalodiphenylsulfone in an organic amide solvent containing waterunder the following conditions (1)-(3):

(1) the molar ratio of the amount of the charged 4,4'-dihalobenzophenoneto the amount of the charged 4,4-dihalodiphenylsulfone being 98:2-65:35,

(2) the ratio of the amount of the charged dihalogenated aromaticcompounds to the amount of the charged alkali metal sulfide being0.95-1.2 (mol/mol),

(3) the reaction being conducted by at least the following two steps:

in the first step, the alkali metal sulfide and the dihalogenatedaromatic compounds being subjected to a polymerization reaction in atemperature range of 60°-260° C. for 0.5-30 hours in thewater-containing organic amide solvent in which the ratio of the watercontent to the amount of the charged organic amide solvent is controlledwithin a range of 1-20 (mol/kg), and

in the second step, the ratio of the water content to the amount of thecharged organic amide solvent being controlled within a range of 7-20(mol/kg), and the polymerization reaction mixture being held for 0.1-10hours in a temperature range of 265°-320° C.

After completion of the second step, the polymerization reaction mixtureis generally cooled to a temperature within a range not higher than 150°C. while stirring it, whereby the resulting copolymer can be easilycollected in the form of granules.

DETAILED DESCRIPTION OF THE INVENTION

Features of the present invention will hereinafter be described indetail.

Production Process of Aromatic Thioether Ketone/Thioether SulfoneCopolymers A. Raw Materials

As raw materials for an aromatic thioether ketone/thioether sulfonecopolymer of this invention, whose crystallization rate has been reducedmoderately (hereinafter abbreviated as "aromatic copolymer"), are useddihalogenated aromatic compounds, an alkali metal sulfide, an organicamide solvent and water as essential components.

Dihalogenated Aromatic Compounds

The random aromatic copolymer according to this invention is synthesizedby using, as dihalogenated aromatic compounds, a 4,4'-dihalobenzophenoneand a 4,4'-dihalodiphenylsulfone in combination with each other.

The 4,4'-dihalobenzophenone is a component which fills the role offorming a constituent for forming a backbone of the aromatic copolymerpermitting easy melt processing and having high melting point and glasstransition temperature. 4,4'-Dichlorobenzophenone and4,4'-dibromobenzophenone are preferred as the 4,4'-dihalobenzophenonefrom the viewpoint of reactivity, economy, and physical properties ofthe resulting aromatic copolymer.

Those whose reactivity to the alkali metal sulfide is near or higherthan that of 4,4'-dihalobenzophenones are classified ashalogen-substituted aromatic compounds of Group (a). In addition to4,4'-dihalobenzophenones, dihalobenzophenones other than 4,4'-isomers,dihalodiphenylsulfone isomers and the like belong to Group (a).

Of these, 4,4'-dihalodiphenylsulfones are excellent as a component fornot only reducing the crystallization rate of the resulting polymer, butalso facilitating the melting and granulation of the aromatic copolymerformed in the polymerization process.

The halogen-substituted aromatic compounds belonging to Group (a), inparticular, 4,4'-dihalodiphenylsulfones, have the following effects: (1)They have a high effect to reduce the crystallization rate and henceshow a sufficient effect by their addition in a small amount. (2) Theyhave reactivity close to that of 4,4'-dihalobenzo-phenones. Therefore,as the fact that monomers having similar reactivity to each other areexcellent in copolymerizability with each other has been described in,for example, "KIRK-OTHMER'S ENCYCLOPEDIA OF CHEMICAL TECHNOLOGY", 3rd.ed., Vol. 6, p. 802, the combination of these monomers generally resultsin a random copolymer when they are polymerized at the same time. (3)The melting point of the resulting aromatic copolymer is not very lowercompared with the PTK homopolymer, but its glass transition temperatureis heightened.

On the other hand, those whose reactivity to the alkali metal sulfide issignificantly lower than that of 4,4'-dihalobenzophenones are classifiedas halogen-substituted aromatic compounds of Group (b). As illustrativecompounds belonging to Group (b), may be mentioned mono-, di- ortri-halogenated or higher polyhalogenated derivatives of aromaticcompounds such as benzene, alkylbenzenes, biphenyl and diphenyl ether.

In addition to the dihalogenated aromatic compounds of Group (a), amono-, di- or tri-halogenated or higher polyhalogenated derivative of anaromatic compound such as benzene, alkylbenzene, biphenyl or diphenylether may be used as a minor component within limits not impairing theobject of this invention. These compounds are useful as an end-cappingagent.

Alkali Metal Sulfide

Illustrative examples of the alkali metal sulfide useful in the practiceof this invention include sodium sulfide, lithium sulfide, potassiumsulfide, rubidium sulfide, cesium sulfide and mixtures of two or morethese compounds.

These alkali metal sulfides can be used as hydrates or aqueous mixtures,or in any anhydrous form. In particular, alkali metal sulfides in theform of a hydrate or aqueous mixture having a water content within therange of the polymerization conditions are advantageous in that adehydration step prior to the polymerization can be omitted.

Among these alkali metal sulfides, sodium sulfide is industriallypreferred for its low price. An alkali metal sulfide which may be formedin situ in the reaction system can also be used.

It is permissible to add a carboxylate or carbonate of an alkali metalor alkaline earth metal within limits not contrary to the object of thisinvention.

Organic Amide Solvent

As reaction media useful for the production process of the aromaticcopolymer according to this invention, aprotic polar organic solventshaving excellent heat stability and alkali resistance can be used. Ofthese, organic amide solvents (including carbamic amides) areparticularly preferred.

As such organic amide solvents, may be mentioned N-methylpyrrolidone,N-ethylpyrrolidone, dimethylimidazolidinone, tetramethylurea,hexamethylphosphoric triamide, dimethylacetamide, etc. Among theseorganic amide solvents, N-methylpyrrolidone is particularly preferredfrom the viewpoint of thermal and chemical stability, the smoothness ofthe polymerization reaction and economy.

B. Polymerization Process and Reaction Conditions

A feature of the production process of the aromatic copolymer accordingto this invention is to use a 4,4'-dihalobenzophenone and a4,4'-dihalodiphenylsulfone as dihalogenated aromatic compounds incombination with each other in a fixed proportion selected. Therecurring units of the formula (II), which are formed by the reaction ofthe 4,4'-dihalodiphenylsulfone with the alkali metal sulfide, reducesthe crystallization rate of the aromatic copolymer.

Another feature of the production process according to this invention isthat the polymerization process comprises at least two steps. Namely,the first step is a process in which the dihalogenated aromaticcompounds of different kinds are subjected to a polymerization reactionwith the alkali metal sulfide in a temperature not higher than 260° C.in a water-containing organic amide solvent to form a prepolymerrequired for a phase-separation polymerization in the second step. Thesecond step subsequent to the first step is a process in which theprepolymer is held for at least 0.1 hours at a temperature not lowerthan 265° C. in a water-containing organic amide solvent. It isconjectured that at this time, the resulting polymer is melted toachieve liquid-liquid phase separation into a polymer melt phase and asolvent phase. In this step, the liquid-liquid phase separation isfacilitated by maintaining a high water content in the organic amidesolvent. After completion of the second step, an intended aromaticcopolymer is provided in the form of granules by cooling the reactionmixture with stirring in accordance with the conventionally-knownmethod.

The polymerization process and reaction conditions will hereinafter bedescribed more specifically.

(1) Composition of dihalogenated aromatic compounds:

In this invention, the dihalogenated aromatic compounds are used as amixture containing a 4,4'-dihalobenzophenone as a major component and a4,4'-dihalodiphenylsulfone as a minor component. The molar ratio of theamount of the charged 4,4'-dihalobenzophenone to the amount of thecharged 4,4'-dihalodiphenylsulfone may desirably be within a range of98:2-65:35, preferably 97:3-75:25, more preferably 96:4-85:15.

Any molar ratios of the 4,4'-dihalodiphenylsulfone to the4,4'-dihalobenzophenone smaller than 2/98 result in a copolymerinsufficiently reduced in crystallization rate. On the other hand, anymolar ratios greater than 35/65 tend to provide an amorphous copolymerhaving no melting point.

(2) Water content:

In the first step of the polymerization, the water content in thereaction system may desirably be within a range of 1-20 moles per kg ofthe amount of the charged organic amide solvent. The use ofwater-containing organic amide solvent having a water content lower than1 mole/kg may possibly induce decomposition in the polymerizationreaction. On the other hand, water contents higher than 20 moles/kg areaccompanied by a potential problem that the polymerization reaction maybe delayed to a too significant extent to provide a copolymer having ahigh molecular weight.

In the second step of the polymerization, the water content maydesirably be within a range of 7-20 moles per kg of the amount of thecharged organic amide solvent. Water contents either lower than 7moles/kg or more than 20 moles/kg involve a potential problem that thegranulation rate of the resulting copolymer may be reduced to asignificant extent. If the organic amide solvent does not contain adesired amount of water after completion of the first step, water may beadded prior to the initiation of the second step to adjust the watercontent in a reaction system to the desired amount.

(3) Composition of monomers charged:

The amount of the charged alkali metal sulfide (including those formedin situ) is within a range of 0.1-5 moles, preferably 0.2-4 mole, morepreferably 0.3-2 moles per kg of the amount of the charged organic amidesolvent. Any amounts less than 0.1 mole/kg result in poor productivityof the polymer and are hence disadvantageous from the economicalviewpoint. Any amounts greater than 5 moles/kg may possibly result in areaction system high in viscosity and hence make it difficult to stirthe reaction system.

The amount of the charged dihalogenated aromatic compounds including the4,4'-dihalobenzophenone and 4,4'-dihalodiphenylsulfone [excluding theamount of the charged halogenated aromatic compound belonging to Group(b)] is within a range of 0.95-1.2 moles, preferably 0.98-1.1 moles,more preferably 1.00-1.05 moles per mole of the amount of the chargedalkali metal sulfide. If this ratio is smaller than 0.95 (mole/mole),there is a potential problem of decomposition during the reaction. Tothe contrary, any ratios greater than 1.2 (mole/mole) may possibly makeit difficult to obtain a polymer having a high molecular weight.

A small portion (desirably not greater than a twentieth of the totalamount of the dihalogenated aromatic compounds) of the dihalogenatedaromatic compounds belonging to Group (a) may be charged right beforethe initiation of the second step or during the second step. Thisfacilitates the provision of an aromatic copolymer high in meltstability. The above-described dihalogenated aromatic compound belongingto Group (b) may be charged during either the first step or the secondstep. It is permissible to add a carboxylate or carbonate of an alkalimetal or alkaline earth metal into the reaction system within limits notimpairing the object of this invention.

(4) First step:

The first step of the polymerization is a preliminary process for thephase-separation polymerization. Namely, in this step, the dihalogenatedaromatic compounds are brought into contact with the alkali metalsulfide to conduct polymerization, thereby forming a prepolymer requiredfor the phase-separation polymerization. This step requires to continuethe polymerization reaction until-it sufficiently proceeds. This step isconducted at a temperature within a range of 60°-260° C., preferably170°-255° C. If the reaction temperature is lower than 60° C., there isa potential problem that the polymerization reaction may be delayed to asignificant extent. On the other hand, any reaction temperatures higherthan 260° C. may possibly induce decomposition during the reaction orresult in an aromatic copolymer deteriorated in melt stability.

The first step is a process in which a prepolymer required for theachievement of phase separation is formed and may desirably be conducteduntil a prepolymer having a solution viscosity (η_(inh)) of at least0.15 dl/g is formed.

The polymerization time in the first step is within a range of 0.5-30hours, preferably 1-20 hours, more preferably 1-10 hours. Any reactiontime shorter than 0.5 hours involves a potential problem of insufficientpolymerization. To the contrary, any reaction time longer than 30 hoursmay possibly induce decomposition during the polymerization reaction orresult in an aromatic copolymer deteriorated in melt stability. Inaddition, any reaction time exceeding 30 hours results in poorproductivity of the polymer and is hence disadvantageous from theeconomical viewpoint.

One of means for reducing the formation of secondary harmful substances,which are considered to attack the resulting polymer to deteriorate it,to provide an aromatic copolymer having high melt stability is toeliminate oxidizing components, in particular oxygen, in both gaseousphase and liquid phase of the reaction system through times of chargingof the monomers, solvent and the like and of polymerization as much aspossible.

In order to eliminate oxygen in the gaseous phase, it is effective, forexample, to completely purge oxygen with an inert gas, to degas thereaction system under reduced pressure, or to make the reaction systemairtight throughout the polymerization reaction. In order to eliminateoxygen in the liquid phase (including an organic amide, water, etc.), itis effective, for example, to use a fresh solvent as distilled, to degasthe liquid phase by boiling or reduction of pressure, or to dilute orpurge oxygen with a pressurized inert gas.

(5) Second step:

The second step of the polymerization is a process of phase-separationpolymerization. Namely, this step is considered to be a process in whichthe prepolymer is melted to form two phases of a molten phase of thearomatic copolymer and a solvent phase during the reaction, the residualalkali metal sulfide, harmful by-products and the like are mostlytransferred to the solvent phase to isolate them, and the polymer ismostly condensed repeatedly in the molten polymer phase without beingattacked by these harmful substances to grow its molecule. As describedabove, this step requires to conduct the reaction in a solvent high inwater content. Therefore, when the water content of the water-containingorganic amide solvent in the first step is low, water may be furtheradded prior to the initiation of this step or during this step, asneeded, to adjust the water content in the reaction system.

The second step is conducted at a temperature within a range of265°-320° C., preferably 280°-310° C. Reaction temperatures lower than265° C. involve a potential problem that the content of granules of theresulting copolymer may be reduced to a significant extent. To thecontrary, reaction temperatures higher than 320° C. are accompanied by apotential problem that decomposition may occur during the reaction, orthe vapor pressure in the reaction system may become unduly high and aparticular pressure reactor is hence required, resulting in aneconomical disadvantage.

The second step is conducted until a polymer having a molecular weightsignificantly higher than that of the prepolymer is formed. Judging fromits solution viscosity, the second step is carried out until a polymerhaving a solution viscosity (η_(inh)) higher than that of the prepolymerby at least 0.05 dl/g, preferably at least 0.10 dl/g is formed.

The second step is conducted for 0.1-10 hours, preferably 0.2-5 hours.Any reaction time shorter than 0.1 hours involves a potential problemthat the content of granules of the resulting copolymer may be reducedto a significant extent. To the contrary, any reaction time exceeding 10hours may possibly result in an aromatic copolymer deteriorated in meltstability, or be too long to conduct the reaction, leading to poorproductivity.

(6) Collection of polymer:

After completion of the second step, the resultant aromatic copolymer isprovided in the form of granules by cooling the reaction mixture withstirring in accordance with the conventionally-known method.

Aromatic Thioether Ketone/Thioether Sulfone Copolymers A. ChemicalStructure

The aromatic copolymers in the form of granules according to the presentinvention are random copolymers having predominant recurring units ofthe formula (I): ##STR3## and containing recurring units of the formula(II): ##STR4## at a ratio of the recurring units (II) to the recurringunits (I), which is within a range of 2/98 to 35/65 (unit/unit),preferably 3/97 to 25/75 (unit/unit), more preferably 4/96 to 15/85(unit/unit).

B. Physical Properties

(1) Solution viscosity (η_(inh)):

When the value of a solution viscosity (η_(inh)) is used as an indexexpressing the molecular weight of a polymer, the copolymers accordingto the present invention are high-molecular weight polymers having asolution viscosity, η_(inh) of at least 0.30 dl/g, preferably at least0.35 dl/g as determined by viscosity measurement at 30° C. and a polymerconcentration of 0.4 g/dl in a 1:1 (by weight) mixed solvent ofm-chlorophenol and 1,2,4-trichlorobenzene.

Any aromatic copolymers, whose η_(inh) is lower than 0.3 dl/g, maypossibly be insufficient in physical properties such as mechanicalproperties. A substantially amorphous sheet of each copolymer, which isalso used in the measurements of Tm and the like as described below, isused as a sample for the measurement of η_(inh).

(2) Melt crystallization time (τ):

The time required for a copolymer to crystallize from its molten stateis a melt crystallization time (τ). Any aromatic copolymers extremelyhigh in crystallization rate, namely, extremely small in the value of τare suitable for use in injection molding and the like, but unsuitablefor use in extrusion because such copolymers forms coarse spherulites inthe course of cooling of its extrudate, resulting in a brittle extrudedproduct. Therefore, they are also unsuitable for use in stretching andsheet forming subsequent to the extrusion because the raw film or sheetobtained by extrusion has already crystallized, whereby difficulties areencountered on stretching or the like. Any copolymers, whose τ is undulysmall, are also difficult to apply to melt spinning, inflation, blowmolding, etc.

Therefore, resins suitable for use in extrusion may desirably be reducedin crystallization rate. When τ is used as an index of extrudability,the value of τ is preferably within a range of 3-15 minutes, preferably3.1-10 minutes.

In this invention, the melt crystallization time, τ means "the timerequired for melt crystallization from the melting point" of eachpolymer sample as determined by a differential scanning calorimeter(DSC) at a cooling rate of 10° C. after the polymer sample is heatedfrom 50° C. to 400° C. at a rate of 100° C./min and at an even speed inan inert gas atmosphere and then held for 1 minute at 400° C. tocompletely melt the polymer sample. The melting point is a valuemeasured in advance in accordance with a method which will be describedsubsequently.

An aromatic copolymer, whose τ is shorter than 3 minutes, has a too highcrystallization rate to apply it to extrusion. To the contrary, anaromatic copolymer, whose τ is longer than 15 minutes, requires anunduly long time for annealing and is hence disadvantageous from theeconomical viewpoint.

(3) Melting point (Tm):

The aromatic copolymers according to the present invention arecrystalline copolymers having a high melting point. Namely, the aromaticcopolymers of this invention are polymers whose melting point, Tm is ashigh as 300°-350° C., preferably 305°-345° C.

(4) Glass transition temperature (Tg):

The aromatic copolymers according to the present invention areheat-resistant resins whose glass transition temperature, Tg is at least125° C., preferably at least 130° C., more preferably at least 135° C.

In the present invention, Tm, ΔHm and Tg of each aromatic copolymersample were measured in the following manner. The copolymer sample ismelted and pressed for 10 seconds at 380° C. in a hot press, and thenplaced into water to quench it, thereby forming a substantiallyamorphous sheet having low degree of crystallinity and a thickness ofabout 0.2 mm. The thus-obtained amorphous sheet was heated by DSC at arate of 10° C./min from 30° C. to 400° C. in an inert gas atmosphere soas to determine its respective values.

(5) Retention (400° C./20 rain) of melt crystallization enthalpy (ΔHmc):

The aromatic copolymers according to this invention are melt-stablepolymers whose retention (400° C./20 min) of melt crystallizationenthalpy (ΔHmc) is generally at least 60%, preferably at least 80%. Inthis invention, the ΔHmc retention (400° C./20 min) is determined bymeasuring, by means of a differential scanning calorimeter, (1) meltcrystallization enthalpy, ΔHmc (400° C./1 min) and (2) meltcrystallization enthalpy, ΔHmc (400° C./21 min) when cooled at a rate of10° C./min from 400° C. after each copolymer sample is held at 50° C.for 5 minutes in an inert gas atmosphere, heated to 400° C. at a rate of100° C./min and then held, respectively, for 1 minute at 400° C. and for21 minutes at 400° C., and then calculating the retention in accordancewith the following equation:

    ΔHmc retention (400° C./20 min)=[ΔHmc (400° C./21 min)/ΔHmc (400° C./1 min)]×100

An aromatic copolymer, whose ΔHmc retention (400° C./20 min) is lowerthan 60%, may possibly be insufficient in long run property and henceinvolves a problem from the viewpoint of practical use.

C. Other Properties

The aromatic copolymers produced in accordance with the process of thisinvention can be collected in the form of granules having an averageparticle size of at least 0.1 mm. The average particle size maydesirably be within a range of preferably 0.15-3.0 mm, more preferably0.2-2.0 mm, most preferably 0.25-1.5 mm. Each of the aromatic copolymerscontains granules having a particle size of at least 0.1 mm in aproportion of at least 70 wt. %, preferably at least 75 wt. %, mostpreferably at least 80 wt. %.

The aromatic copolymers are granular resins having a bulk specificgravity (apparent specific gravity: bulk density) of generally 0.15-0.6g/cc, preferably 0.2-0.5 g/cc, more preferably 0.25-0.4 g/cc.

The granular resins are extremely easy to collect as described above andin addition, are excellent in handling properties in metering, charging,storing, shipping, etc. because they are also excellent in free-flowingproperties and also superb in blocking resistance in a hopper for aforming or molding machine upon forming or molding. Therefore, they haveextremely great advantages from the viewpoint of practical use.

The aromatic copolymers according to this invention are soluble in, forexample, a mixed solvent of chlorophenol and trichlorobenzene and thelike in a low-crystalline state. These solutions can be used in castmolding, coating and the like. It is however possible to make thesecopolymers insoluble by crystallizing them after molding.

Forming or Molding Products

The aromatic copolymers according to this invention can be mostpreferably used either singly or as blends with other thermoplasticresins, various kinds of reinforcing fibers, various kinds of inorganicfillers and/or the like in extrusion, and stretching, sheet forming andthe like subsequent to the extrusion. In addition, they can be appliedto melt stretching and spinning, inflation, blow molding, injectionmolding and the like. Further, their solutions can be applied to castingprocesses.

These processing methods can be used either singly or in combination toform or mold into various products, for example, stretched films(including lubricating films), unstretched films, sheets, plates, rods,pipes, tubes, profiles, multifilaments, monofilaments, fabrics, unwovenfabrics, split yarns, prepregs, general molded products, etc.

For example, oxides, hydroxides, carbonates, organic acid salts and thelike of metals such as Ba, Sr, Ca, Mg, Zn and Li are useful asstabilizers in melt processing for the aromatic copolymers according tothis invention.

Various formed and molded products obtained by using the aromaticcopolymer of this invention combine excellent heat resistance inherentin the aromatic copolymer with good mechanical properties. As specificexample of formed products obtained, may be mentioned unstretched films,stretched films, unstretched fibers and stretched fibers having thefollowing respective physical properties. These formed products includethose produced not only by using the aromatic copolymer according tothis invention alone, but also by using thermoplastic compositionscomprising as a principal component, the aromatic copolymer of thisinvention, i.e., thermoplastic compositions comprising one or more otherthermoplastic resins in a proportion of 50 wt. % or lower, preferably 30wt. % or lower, more preferably 15 wt. % or lower.

The use of the aromatic copolymers of this invention permits theproduction of unstretched films having the following physical properties(a)-(d):

(a) density: at least 1.30 g/cm³,

(b) elastic modulus: at least 100 kg/mm²,

(c) strength: at least 3 kg/mm², and

(d) thickness: 0.001-1 mm.

The use of the aromatic copolymers of this invention permits theproduction of stretched films having the following physical properties(a)-(d):

(a) density: at least 1.34 g/cm³,

(b) elastic modulus: at least 100 kg/mm²,

(c) strength: at least 3 kg/mm², and

(d) thickness: 0.001-1 mm.

The use of the aromatic copolymers of this invention permits theproduction of unstretched fibers having the following physicalproperties (a)-(d):

(a) density: at least 1.30 g/cm³,

(b) elastic modulus: at least 150 kg/mm²,

(c) strength: at least 5 kg/mm², and

(d) fiber diameter: 0.001-1 mm.

The use of the aromatic copolymers of this invention permits theproduction of stretched fibers having the following physical properties(a)-(d):

(a) density: at least 1.34 g/cm³,

(b) elastic modulus: at least 200 kg/mm²,

(c) strength: at least 5 kg/mm², and

(d) fiber diameter: 0.001-1 mm.

Application Fields

The aromatic copolymers according to the present invention have goodproperties such as high melting point, high glass transitiontemperature, electronic insulating property, chemical resistance andoxidation resistance and can hence be used in various fields, forexample, as electric parts (connectors, sealants, films for magneticrecording, capacitor films, FPCs, tape carriers, insulating films,insulating papers, plastic magnets, etc.), mechanical parts (cameraparts, watch and clock parts, sliding parts, etc.), car parts(carburetors, canisters, reflectors, etc.), and so on by making the bestuse of these properties. In addition to the formed and molded products,they may be used as coating materials, caulking materials and the likein the form of powder or a solution.

ADVANTAGES OF THE INVENTION

The present invention can provide granular aromatic thioetherketone/thioether sulfone copolymers combining a high melting point witha high glass transition temperature and having sufficient melt stabilityand improved extrudability.

The aromatic thioether ketone/thioether sulfone copolymers according tothis invention are reduced in crystallization rate and hence suitablefor use, particularly, in extrusion.

The aromatic thioether ketone/thioether sulfone copolymers according tothis invention can be collected in the form of granules. Therefore, theyare good in handling properties in filtration, washing, drying, shippingand the like, for example, in a collection step after polymerization andcan also be easy to handle upon forming or molding.

According to the production process of the present invention, it ispossible to economically and industrially produce aromatic copolymerscombining a high melting point with a high glass transition temperature.Their applications can hence be developed into electronic and mechanicalfields, and the like, in which suitable materials have heretofore notexisted, or if any, their use has been limited due to their extremelyhigh prices.

EMBODIMENTS OF THE INVENTION

The present invention will hereinafter be described specifically by thefollowing examples and comparative examples. It should however be bornein mind that the present invention is not limited only to the followingexamples.

Examples 1-7

A titanium-lined autoclave equipped with a stirrer was charged with NMP(N-methylpyrrolidone) as an organic amide solvent and Na₂ S·nH₂ O(n=5.06) as an alkali metal sulfide in respective proportions given inTable 1.After distilling out part of water of hydration as needed, theautoclave was charged with 4,4'-dichlorobenzophenone and4,4'-dichlorodiphenylsulfone and optionally distilled water. Thecompositions of the charged components are as shown in Table 1.

After the autoclave being purged with nitrogen, the respective contentswere heated with stirring to perform the respective first steps.Incidentally, in Examples 3, 6 and 7, degassing under reduced pressure(for about 10 minutes at about 30 Torr) was conducted prior to thepurging with nitrogen. In the first steps of Examples 2 and 5, heatingwas conducted for 1 hour at 180° C. and then for 2 hours at 200° C. asshown in Table 1.

After completion of the respective first steps, water was further addedas needed, and the contents were further heated with stirring to performthe respective second steps. The amounts of the additionally chargedwater and other polymerization conditions are as shown in Table 1.

After completion of the respective second steps, each of the reactionmixtures was cooled to room temperature while stirring it, therebycompleting granulation.

Each of the reaction mixtures was taken out of the autoclave and diluteddouble by volume with NMP. The reaction mixture diluted with NMP wasfiltered through a filter paper to separate solids. The thus-obtainedsolids were washed with acetone, then dispersed in acetone to form aslurry. The resulting slurry was sifted by a screen having an openingsize of 0.1 mm to divide the solids into 0.1 mm-on granules and 0.1mm-pass fine powder. The thus-obtained granules and powder wereseparately washed with water and dried at about 100° C. The content ofthe granules was determined from the ratio of the weight (g) of thegranules to the total weight (g) of the granules and the powder.

The proportions of C, H and S in the thus-obtained granules weredetermined by elemental analysis, thereby calculating compositionalvalues of each copolymer. The results are given collectively in Table 2.

With respect to the respective granule samples, their solutionviscosities, η_(inh), which serve as an index of their molecularweights, were determined in the following manner. Each of the granulesamples was melted under heat in a hot press, pressed and then quenchedto form a substantially amorphous sheet having a thickness of about 0.2mm. A portion thereof was dissolved in a 1:1 (by weight) mixed solventof m-chlorophenol and 1,2,4-trichlorobenzene to measure its solutionviscosity at 30° C. and a polymer concentration of about 0.4 g/dl. Theresults are shown in Table 2.

With respect to thermal properties, Tg and Tm were measured by heatingeach amorphous sheet by means of DSC at a rate of 10° C./min from 30° C.to 400° C. in an inert gas atmosphere.

The retention of melt crystallization enthalpy (ΔHmc) was measured andcalculated in the following manner. Each polymer sample was held at 50°C. for 5 minutes in an inert gas atmosphere by means of a differentialscanning calorimeter, quickly heated from 50° C. to 400° C. at a rate of100° C./min, held for 1 minute at 400° C. to completely melt the polymersample and then cooled at a rate of 10° C./min to measure ΔHmc (400°C./1 min). On the other hand, the polymer sample was quickly heated from50° C. to 400° C. at a rate of 100° C./min in the same manner asdescribed above, held for 21 minutes at 400° C in the molten state andthen cooled at a rate of 10° C./min to measure ΔHmc (400° C./21 min).

The ΔHmc retention was calculated in accordance with the followingequation:

    ΔHmc retention (400° C./20 min)=[ΔHmc (400° C./21 min)/ΔHmc (400° C./1 min)]×100

The melt crystallization time, τ was determined by measuring "the timerequired for melt crystallization from the melting point" of eachpolymer sample by means of a differential scanning calorimeter (DSC)when cooled at a rate of 10° C. from 400° C. after the polymer samplewas heated from 50° C. to 400° C. at a rate of 100° C./min in an inertgas atmosphere, then held for 1 minute at 400° C. to completely melt thepolymer sample.

The results are given collectively in Table 2.

Comparative Examples 1-4

In Comparative Examples 1-3, polymerization was conducted under the sameconditions as in Example 2 or 3 except that the compositions of thecharged 4,4'-dichlorobenzophenone and 4,4'-dichlorodiphenylsulfone werechanged. In Comparative Example 4, polymerization was conducted underthe same conditions as in Example 1 except that the polymerization inthe first step was conducted in a time as short as 0.3 hours.

Since a granular polymer was obtained in Comparative Example 3, thispolymer was used. In Comparative Examples 1 and 2, polymers in the formof substantially fine powder were only able to be obtained. Therefore,these polymers were formed respectively into substantially amorphoussheets having a thickness of about 0.2 mm by hot pressing to determinethe solution viscosities, η_(inh) and thermal properties of theamorphous sheets thus formed.

The polymer obtained in Comparative Example 4 was too low in molecularweight to form into a sheet. Therefore, the measurements of itscomposition, η_(inh) and thermal properties were omitted.

Comparative Example 5

A titanium-lined autoclave was charged with 320 g of hydrated sodiumsulfide (water content: 53.8 wt. %) and 600 g of NMP. While heating thecontents to 200° C., 130 g of water, 110 g of NMP and 1.3 g of H₂ S weredistilled out. Thereafter, 10 g of water, 191 g of p-dichlorobenzene and435 g of NMP were fed, followed by heating of the contents for 4 hoursat 220° C. and further for 4 hours at 230° C., thereby preparing areaction solution.

An autoclave was charged with 501 g of the reaction solution thusobtained, 8.0 g of hydrated sodium sulfide (water content: 53.8 wt. %),63.4 g of 4,4'-dichlorobenzophenone, 278 g of NMP and 90 g of water.After the autoclave being purged with nitrogen, the contents werereacted for 30 minutes at 265° C.

A liquid mixture of 4,4'-dichlorobenzophenone and 70 g of NMP was fed,followed by heating of the contents for 30 minutes at 240° C. Aftercompletion of the polymerization reaction, a polymer in the form ofgranules was collected in the same manner as in Example 1.

This polymer was an aromatic thioether ketone/thioether block copolymercomprising at least one poly(phenylene thioether-ketone) blockrepresented by the formula: ##STR5## and at least one poly(phenylenethioether) block represented by the formula: ##STR6##

The composition and thermal properties of the granular block copolymerthus obtained were determined. The results are given collectively inTable 2.

                                      TABLE 1                                     __________________________________________________________________________    First step                             Second step                                             --CO--                                                                             --SO.sub.2 --                                                                      DCB         Water                                                                             Monomer                                                                             inh of                       NMP     Na.sub.2 S                                                                         Water                                                                             (*1) (*2) (*4)                                                                              Temp                                                                              Time                                                                              added                                                                             added (*5)                                                                          prepolymer                                                                          Temp Time              (kg)    (mol)                                                                              (mol)                                                                             (mol)                                                                              (mol)                                                                              (mol)                                                                             (°C.)                                                                      (hrs)                                                                             (mol)                                                                             (mol) (dl/g)                                                                              (°C.)                                                                       (hrs)             __________________________________________________________________________    Ex. 1                                                                             2.00                                                                              1.51 9.8 1.37 0.15 --  200 3   7.2 --    0.22  291  0.5               Ex. 2                                                                             2.00                                                                              1.51 17.0                                                                              1.44 0.08 --  180 1   0   0.03  0.33  292  0.5                                              200 2       (*3)                               Ex. 3                                                                             2.00                                                                              1.50 23.2                                                                              1.23 0.31 --  220 3   0   0.06  0.25  282  0.5                                                          (*1)                               Ex. 4                                                                             2.00                                                                              1.51 17.0                                                                              1.37 0.15 --  140 6   0   0.03  0.20  291  0.5                                                          (*1)                               Ex. 5                                                                             2.00                                                                              1.51 17.0                                                                              1.37 0.15 0.15                                                                              180 1   0   --    0.21  291  0.5                                              200 2                                          Ex. 6                                                                             2.00                                                                              1.92 18.8                                                                              1.72 0.20 --  220 1   0   0.08  0.32  295  0.3                                              245 1       (*1)                               Ex. 7                                                                             2.00                                                                              2.06 18.7                                                                              1.96 0.10 --  220 1   0   0.08  0.30  300  0.3                                              245 1.5     (*1)                               Comp.                                                                             2.00                                                                              1.51 17.0                                                                              1.52 0    --  180 1   0   0.03  0.31  292  0.5               Ex. 1                          200 2       (*3)                               Comp.                                                                             2.00                                                                              1.51 17.0                                                                              1.51 0.01 --  180 1   0   0.03  0.26  292  0.5               Ex. 2                          200 2       (*3)                               Comp.                                                                             2.00                                                                              1.51 10.0                                                                              0.83 0.69 --  200 3   10.0                                                                              --    0.19  270  0.5               Ex. 3                                                                         Comp.                                                                             2.00                                                                              1.51 17.0                                                                              1.37 0.15 --  200 0.3 0   --    <0.10 291  0.5               Ex. 4                                                                         __________________________________________________________________________     (Notes)                                                                       *1: 4,4Dichlorobenzophenone.                                                  *2: 4,4Dichlorodiphenylsulfone.                                               *3: 1,2,4Trichlorobenzene.                                                    *4: 1,4Dichlorobenzene.                                                       *5: Monomer added was dissolved in 30 g of NMP before charging           

                                      TABLE 2                                     __________________________________________________________________________                         Melt               Average                                                                             Apparent                        Content of                                                                              Composition                                                                              crystallization                                                                             ΔHmc                                                                         particle                                                                            specific                        granules  (*9)   ηinh                                                                          time τ                                                                           Tg Tm  retention                                                                          size (*6)                                                                           gravity (*7)                    (wt. %)   (unit/unit)                                                                          (dl/g)                                                                            (min)  (°C.)                                                                     (°C.)                                                                      (%)  (mm)  (g/cc)                          __________________________________________________________________________    Ex. 1                                                                             96    90/10  0.54                                                                              3.6    139                                                                              331 80   0.40  0.29                            Ex. 2                                                                             93    95/5   0.55                                                                              3.5    137                                                                              341 85   0.35  0.35                            Ex. 3                                                                             96    79/21  0.59                                                                              4.2    150                                                                              310 96   0.62  0.33                            Ex. 4                                                                             98    90/10  0.52                                                                              3.7    140                                                                              331 85   0.45  0.30                            Ex. 5                                                                             91    89/11  0.46                                                                              3.7    140                                                                              332 82   0.37  0.36                            Ex. 6                                                                             97    90/10  0.53                                                                              3.5    139                                                                              333 92   0.39  0.30                            Ex. 7                                                                             96    95/5   0.51                                                                              3.4    137                                                                              341 91   0.40  0.35                            Comp.                                                                              2    100/0  0.60                                                                              2.4    135                                                                              351 83   <<0.10                                                                              --                              Ex. 1                                   (*8)                                  Comp.                                                                              6    99/1   0.59                                                                              2.4    136                                                                              347 82   <<0.10                                                                              --                              Ex. 2                                    (*8)                                 Comp.                                                                             95    52/48  0.40                                                                              --     163                                                                              None                                                                              --   0.45  0.35                            Ex. 3                                                                         Comp.                                                                             Granular                                                                            (*10)  --  --     114                                                                              313 --   0.38  0.33                            Ex. 5                                                                         __________________________________________________________________________     *6: Measured in accordance with JIS K0069-31 (values for granules).           *7: Measured in accordance with JIS K6721-33 (values for granules).           *8: Values for the whole resin collected.                                     *9: Compositional ratio of recurring units (I) to recurring units (II).       *10: Compositional ratio of recurring units (I) to phenylene thioether        recurring units of 33/67 (unit/unit).                                    

Example 8

(1) Unstretched film (FN-6):

Ten batch processes of polymerization were conducted in accordance withthe same formulation as in Example 6. Ten batches of the polymer thusobtained were mixed with each other to provide Resin (P-6). Resin (P-6)was found to have a compositional ratio of the recurring units (I) tothe recurring units (II) of 90:10 (unit/unit) and η_(inh) of 0.51 dl/gfrom the results of its elemental analysis and solution viscositymeasurement.

To 100 parts by weight of Resin (P-6), were added 0.45 parts by weightof strontium carbonate and 0.05 parts by weight of slaked lime. Theywere then intimately mixed in a Henschel mixer into a blend. Thethus-obtained blend was extruded in the form of a strand through atwin-screw midget extruder equipped with a nozzle 3 mm across at amelting temperature of 340° C. The extrudate was quenched and thenchopped into pellets. These pellets were crystallized at 155° C. toobtain a pellet sample (PL-6).

A portion of the pellet sample (PL-6) was melt-extruded through anextruder having a cylinder diameter of 35 mm and an L/D ratio of 28 andequipped with a T-die having a lip clearance of 0.5 mm and a width of250 mm. The melt extrusion temperature was preset to 340° C. Thethus-extruded resin was pressed against a casting drum controlled atabout 90° C. by applying a static potential of 5.6 KV via a pinningapparatus to cool the resin, thereby obtaining an unstretched thick film(FN-6) having an average thickness of about 0.2 mm. This unstretchedthick film (FN-6) was transparent and substantially amorphous.

(2) Unstretched film (FN-7):

Ten batch processes of polymerization were conducted in accordance withthe same formulation as in Example 7. Ten batches of the polymer thusobtained were mixed with each other to provide Resin (P-7). Resin (P-7)was found to have a compositional ratio of the recurring units (I) tothe recurring units (II) of 95:5 (unit/unit) and η_(inh) of 0.50 dl/gfrom the results of its elemental analysis and solution viscositymeasurement.

To 100 parts by weight of Resin (P-7), were added 0.45 parts by weightof strontium carbonate and 0.05 parts by weight of slaked lime. Theywere then intimately mixed in a Henschel mixer into a blend. Thethus-obtained blend was extruded in the form of a strand through atwin-screw midget extruder equipped with a nozzle 3 mm across at amelting temperature of 350° C. The extrudate was quenched and thenchopped into pellets. These pellets were crystallized at 155° C. toobtain a pellet sample (PL-7).

A portion of the pellet sample (PL-7) was melt-extruded through anextruder having a cylinder diameter of 35 mm and an L/D ratio of 28 andequipped with a T-die having a lip clearance of 0.5 mm and a width of250 mm. The melt extrusion temperature was preset to 350° C. Thethus-extruded resin was pressed against a casting drum controlled atabout 90° C. by applying a static potential of 5.6 KV via a pinningapparatus to cool the resin, thereby obtaining an unstretched thick film(FN-7) having an average thickness of about 0.2 mm. This unstretchedthick film (FN-7) was transparent and substantially amorphous.

(3) Unstretched film (FN-Cl):

Ten batch processes of polymerization were conducted in accordance withthe same formulation as in Comparative Example 1. Ten batches of thepolymer thus obtained were mixed with each other to provide Resin(P-C1). Resin (P-C1) was found to have a compositional ratio of therecurring units (I) to the recurring units (II) of 100:0 (unit/unit) andη_(inh) of 0.60 dl/g from the results of its elemental analysis andsolution viscosity measurement.

To 100 parts by weight of Resin (P-C1), were added 0.45 parts by weightof strontium carbonate and 0.05 parts by weight of slaked lime. Theywere then intimately mixed in a Henschel mixer into a blend. Thethus-obtained blend was extruded in the form of a strand through atwin-screw midget extruder equipped with a nozzle 3 mm across at amelting temperature of 360° C. The extrudate was quenched and thenchopped into pellets. These pellets were crystallized at 155° C. toobtain a pellet sample (PL-C1).

A portion of the pellet sample (PL-C1) was melt-extruded through anextruder having a cylinder diameter of 35 mm and an L/D ratio of 28 andequipped with a T-die having a lip clearance of 0.5 mm and a width of250 mm. The melt extrusion temperature was preset to 360° C. Thethus-extruded resin was pressed against a casting drum controlled atabout 90° C. by applying a static potential of 5.6 KV via a pinningapparatus to cool the resin, thereby obtaining an unstretched thick film(FN-C1) having an average thickness of about 0.2 mm. This unstretchedthick film (FN-C1) was opaque. This is considered that since the valueof τ of Resin (P-C1) is too small, the film was undergone partiallycrystallization during cooling in the case of this thick film.

(4) Stretched film (FH-6):

The unstretched thick film (FN-6) was stretched 2.5 times in the machinedirection and 2.5 times in the transverse direction at a stretchingtemperature of 160° C. by a biaxial stretching machine (manufactured byToyo Seiki Seisakusho, Ltd.), thereby obtaining a biaxially-stretchedfilm with ease. The biaxially-stretched film thus obtained was fixed toa metal frame along the entire periphery thereof to heat set the filmfor 10 minutes at 250° C. in a Geer oven while maintaining the length ofthe film constant, thereby obtaining a stretched and heat-set film(FH-6).

(5) Stretched film (FH-7):

The unstretched thick film (FN-7) was stretched 2.5 times in the machinedirection and 2.5 times in the transverse direction at a stretchingtemperature of 160° C. by the biaxial stretching machine (manufacturedby Toyo Seiki Seisakusho, Ltd.), thereby obtaining a biaxially-stretchedfilm with ease. The biaxially-stretched film thus obtained was fixed toa metal frame along the entire periphery thereof to heat set the filmfor 10 minutes at 250° C. in a Geer oven while maintaining the length ofthe film constant, thereby obtaining a stretched and heat-set film(FH-7).

(6) Trial production of stretched film (FH-C1):

The unstretched thick film (FN-C1) was stretched 2.5 times in themachine direction and 2.5 times in the transverse direction at astretching temperature of 160° C. by the biaxial stretching machine(manufactured by Toyo Seiki Seisakusho, Ltd.). However, since theunstretched film (FN-C1) partially crystallized, it was considerablydifficult to produce a biaxially-stretched film, so that the film brokeduring the stretching process. It was therefore impossible to obtain abiaxially-stretched film which-was satisfactory.

The physical properties of the respective unstretched films andstretched films thus obtained were measured.

The results are given collectively in Table 3.

                  TABLE 3                                                         ______________________________________                                                   Sample                                                                        FN-6  FN-7    FN-C1   FH-6  FH-7                                   ______________________________________                                        Composition  90/10   95/5    100/0 90/10 95/5                                 (unit/unit)                                                                   Thickness (mm)                                                                             0.209   0.204   0.200 0.033 0.033                                Density*.sup.11 (g/cm.sup.3)                                                               1.31    1.31    1.31  1.36  1.36                                 Strength*.sup.12 (kg/mm.sup.2)                                                             10.0    10.5    9.0   10.0  10.5                                 Elastic modulus*.sup.12                                                       (kg/mm.sup.2)                                                                              270     300     250   270   300                                  Elongation*.sup.12 (%)                                                                     9       13      12    9     20                                   Surface roughness,                                                                         --      --      --    0.05  0.07                                 Ra*.sup.13 (μm)                                                            Coefficient of surface                                                                     --      --      --    0.3   0.4                                  dynamic friction                                                              (against Teflon)*.sup.14                                                      Heat shrinking*.sup.15                                                                     --      --      --    2     1                                    rate (320° C.) (%)                                                     Solder heat*.sup.16                                                                        Blist   Blist   Blist NC    NC                                   resistance (320° C.)                                                   ______________________________________                                         (Notes)                                                                       Blist: Blistered. NC: Not changed.                                            *.sup.11 : Density was measured at 23° C. by using a lithium           bromide/water system density gradient tube.                                   *.sup.12 : Strength, elastic modulus and elongation were measured by usin     TENSILON (manufactured by Toyo Boldwin Co., Ltd.) in accordance with ASTM     D638.                                                                         *.sup.13 : Surface roughness, Ra (μm) was measured by using a surface      roughness meter (SURFCOM 550A, manufactured by Tokyo Seimitsu Co., Ltd.)      in accordance with JIS B0601.                                                 *.sup.14 : Coefficient of surface dynamic friction was measured by using      "Friction Meter TR Model" (manufactured by Toyo Seiki Seisakusho, Ltd.) i     accordance with ASTM D1894.                                                   *.sup.15 : Heat shrinking rate was determined by heating each film sample     for 10 minutes in a Geer oven controlled at 320° C.                    *.sup.16 : Solder heat resistance was determined by visually observing th     condition of each film sample after immersed for 10 seconds in a solder       bath in accordance with JIS C6481 (1976).                                

Example 9

(1) Unstretched fibers (SN-6) and stretched fibers (SH-6):

A portion of Resin (P-6) obtained in Example 8 was extruded through aCapirograph (manufactured by Toyo Seiki Seisakusho, Ltd.) equipped witha nozzle having a diameter of 1.0 mm and an L/D ratio of 10 at anextrusion speed of 10 mm/sec and an extrusion temperature of 350° C. Theextrudate was then quenched in cooling air to obtain unstretched fibers(SN-6). Their average diameter was 0.24 mm.

The unstretched fibers (SN-6) were stretched 4 times at 157°-158° C. byTENSILON (manufactured by Toyo Boldwin Co., Ltd.). The stretched fibersthus obtained were heat set for 5 minutes at 320° C. in a Geer oven,thereby obtaining stretched and heat-set fibers (SH-6).

(2) Unstretched fibers (SN-7) and stretched fibers (SH-7):

A portion of Resin (P-7) obtained in Example 8 was extruded through aCapirograph (manufactured by Toyo Seiki Seisakusho, Ltd.) equipped witha nozzle having a diameter of 1.0 mm and an L/D ratio of 10 at anextrusion speed of 10 mm/sec and an extrusion temperature of 360° C. Theextrudate was then quenched in cooling air to obtain unstretched fibers(SN-7). Their average diameter was 0.20 mm.

The unstretched fibers (SN-7) were stretched 4 times at 157°-158° C. byTENSILON (manufactured by Toyo Boldwin Co., Ltd.). The stretched fibersthus obtained were heat set for 5 minutes at 320° C. in a Geer oven,thereby obtaining stretched and heat-set fibers (SH-7).

(3) Unstretched fibers (SN-C1) and stretched fibers (SH-C1):

A portion of Resin (P-C1) obtained in Example 8 was extruded through aCapirograph (manufactured by Toyo Seiki Seisakusho, Ltd.) equipped witha nozzle having a diameter of 1.0 mm and an L/D ratio of 10 at anextrusion speed of 10 mm/sec and an extrusion temperature of 370° C. Theextrudate was then quenched in cooling air to obtain unstretched fibers(SN-C1). Their average diameter was 0.22 mm.

The unstretched fibers (SN-C1) were stretched 4 times at 157°-158° C. byTENSILON (manufactured by Toyo Boldwin Co., Ltd.). The stretched fibersthus obtained were heat set for 5 minutes at 320° C. in a Geer oven,thereby obtaining stretched and heat-set fibers (SH-C1).

The physical properties of the respective unstretched fibers andstretched and heat-set fibers thus obtained were measured.

The results are given collectively in Table 4.

                  TABLE 4                                                         ______________________________________                                               Sample                                                                        SN-6  SN-7    SN-C1   SH-6  SH-7  SH-C1                                ______________________________________                                        Composition                                                                            90/10   95/5    100/0 90/10 95/5  100/0                              (unit/unit)                                                                   Fiber dia-                                                                             0.24    0.20    0.22  0.10  0.08  0.09                               meter (mm)                                                                    Density*.sup.11                                                                        1.31    1.31    1.31  1.35  1.35  1.35                               (g/cm.sup.3)                                                                  Strength*.sup.17                                                                       11      10      10    24    41    35                                 (kg/mm.sup.2)                                                                 Elastic modu-                                                                          180     260     260   470   700   680                                lus*.sup.17                                                                   (kg/mm.sup.2)                                                                 Elonga-  170     260     250   39    26    25                                 tion*.sup.17 (%)                                                              Heat shrink-                                                                           --      --      --    2     1     1                                  ing*.sup.15                                                                   rate (320° C.)                                                         ______________________________________                                         (Notes)                                                                       *.sup.11 and *.sup.15 : See Notes in Table 3.                                 *.sup.17 : Strength, elastic modulus and elongation were measured by usin     TENSILON (manufactured by Toyo Boldwin Co., Ltd.) at a drawing rate of 50     mm/min and 23° C.                                                 

What is claimed is:
 1. A process for the production of an aromaticthioether ketone/thioether sulfone copolymer, which comprises reactingan alkali metal sulfide with dihalogenated aromatic compounds includinga 4,4'-dihalobenzophenone and a 4,4'-dihalodiphenylsulfone in an organicamide solvent containing water under the following conditions(1)-(3):(1) the molar ratio of the amount of the charged4,4'-dihalobenzophenone to the amount of the charged4,4'-dihalodiphenylsulfone being 98:2-65:35, (2) the ratio of the amountof the charged dihalogenated aromatic compounds to the amount of thecharged alkali metal sulfide being 0.95-1.2 (mol/mol), (3) the reactionbeing conducted by at least the following two steps: in the first step,the alkali metal sulfide and the dihalogenated aromatic compounds beingsubjected to a polymerization reaction in a temperature range of60°-260° C. for 0.5-30 hours in the water-containing organic amidesolvent in which the ratio of the water content to the amount of thecharged organic amide solvent is controlled within a range of 1-20(mol/kg), and in the second step, the ratio of the water content to theamount of the charged organic amide solvent being controlled within arange of 1-20 (mol/kg), and the polymerization reaction mixture beingheld for 0.1-10 hours in a temperature range of 265°-320° C.
 2. Theprocess as claimed in claim 1, wherein the amount of the charged alkalimetal sulfide is 0.1-5 moles per kg of the amount of the charged organicamide solvent.
 3. The process as claimed in claim 1, wherein thepolymerization reaction in the first step is conducted until aprepolymer having a solution viscosity (η_(inh)) of at least 0.15 dl/gis formed.
 4. The process as claimed in claim 1, wherein thepolymerization reaction in the second step is conducted until thesolution viscosity (η_(inh)) of the prepolymer formed in the first stepincreases by at least 0.05 dl/g.
 5. The process as claimed in claim 1,wherein oxidizing components in both gaseous phase and liquid phase ofthe reaction system are eliminated prior to the initiation of thepolymerization reaction.
 6. The process as claimed in claim 1, hereinthe resulting aromatic thioether ketone/thioether sulfone copolymer iscollected in the form of granules having an average particle size withina range of 0.15-3.0 mm, at least 70 weight % of said granules having aparticle size of at least 0.1 mm.